These are three mortal manufacturing sins Preventing Defect Recurrence etc.

Fundamentals of Improvement How to do Kaizen?

Q
U • Improvements do not come about by coincidence. It Kaizen (or) Improvement Process can be broken into 2
A is the result of conscious efforts towards them. Some steps:
L useful clues towards this are:
I 1 Problem Identification &
T • Start with small improvements
2 Problem Solving
Y • Start with our problem and not their problem
Problem is defined as the “deviation from the standard”.
T • Start with easy areas It is the difference between what is expected and what is
O actually occurring. Solution is that which can eliminate or
• Make improvements a daily part of routine
O reduce the difference between the actual and expectation
L • Use group collective wisdom for continuous
S improvement Problem Identification
• Never reject an idea before trying • Understand thoroughly what is happening
• Highlight problems, do not hide them • Question every activity and result of every action
• Do not be afraid of work stoppage • Compare them with standard
Areas of Kaizen
• Never accept status quo
Cost & Time Reduction
• Look where maximum dissatisfaction
Safety
• Look for problems where you think none exist
Waste Elimination
Productivity Improvement • Look at things from customers point of view in terms of
Quality Cost, Delivery
Energy Conservation
Fatigue Reduction Problem Solving
Customer Service • Steps to Problem solving should be:
Quality Improvement • Analysis to find root-cause of the problem
System Introduction • Idea Formulation
Visual Control System
• Idea Selection
5S (House Keeping)
• Improvement

• Sustain Gains

148 Employability Skills - (NSQF) Quality Tools : Theory 2.5.65

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